Job
Description
Plant Accountability
- Accountable for entire operations of SILO, TANK processes in the plant.- Accountable for heading 97 Staff & 700 Workers and managing the areas as Production, Engineering, PPC, Stores, QA, Maintenance & Utilities, Administration, Accounts & Logistics.- Accountable for achievement of MFO Targets in terms of Safety, Quality, Cost, Delivery and Morale.Production Planning- Planning day-to-day activities, production schedules, implementing quality tools and allocating work for achieving of monthly production targets.- Strategic planning for capacity enhancements of complete manufacturing operations for more than ___ crores of turnover this year & ensuring smooth functioning of the plant to achieve the set targets as per quality standards.- Appraising the prevalent production systems/ processes, identifying loopholes, if any and undertaking result-oriented measures for alleviating them.- Leading a team of Engineers, Science Graduates and contract workman's for achieving the monthly business plan targets of production.- Set up goals for cost reductions & savings.Plant Operations- Getting maximum production with the required yield as well as Optimizing man power & machinery utilization to achieve pre-set targets compliance with the quality & time.- Monitoring daily production & consumption of inventory, coordinating with material section for raw material planning based on consumption and overall logistics planning.- Focus on Material Balancing, Costing, Loss and recovery calculations.- Conceptualizing & implementing projects, annual improvement plans for production reengineering, technology absorption projects for expansion and new products.- Identifying areas of obstruction/ breakdowns and take steps to rectify the trouble shooting operational problems and continuously monitoring the plant performance.- Daily Review meeting with all concerned HODs for last day's failure analysis along with corrective action plan & current day's & future targets analysis.- Minimizing performance bottlenecks for achieving high productivity with maximization of material & machine.- Coordinating material spare parts planning related activities encompassing identification of vendors, requirement of specification and offer evaluation. -- - Planning and executing capital procurement.- Monitoring of consumables in terms of Quality, Consumption and Inventory management of the same.- Set up standard operating procedure for individual process from Raw material input through gate to FG out from gate. - Set up and monitor daily, weekly and monthly production target and plan for raw material, consumable. Follow up and modify the entire plan as per customer need.Quality Assurance- Ensuring the Quality check of incoming raw material.- Ensure stringent sample quality checks at each stage of production process on all critical product parameters.- Analysis of quality related problems based on the data, identification of bottlenecks and key issues. Modification of the process route and equipment for - the better productivity and quality.- Quality defect analysis by seven quality tools and six sigma method.- Ensuring continual improvement for productivity, quality & process as a core member of the team.- Training and guiding teams on towards identifying factors critical to quality, reducing process variation, improving capabilities & increasing stability.Process Improvements- Ensure robust process and expansion of plant.- Ensure Process Improvement to make uninterrupted quality product.- Introduce Mechanical and Electrical Poka yoke to ensure Quality products.- Reduction in cycle times to meet increasing customer demands.- Study of process to reduce in house rejection.- Focus on New product development.Manpower Management- Identifying the manpower requirement on daily basis based on the production plan.- Plan and monitor deployment of Workers as per the work plan.- Monitoring the performance level of the staff & workers for ensuring accomplishment of the target.- Organizing regular periodic meetings & trainings for staff & engineers for discussing current work issues and devising solutions for enhanced operations.- Imparting floor training to operating people for enhancing their knowledge and improving the efficiency.Inventory Management- Ensure inventory in Receipt store and FGS.- Control of Inventory by monitoring Min - Max level, Inventory Turn Ratio and dead inventory.- Ensure tool and maintenance store inventory control and availability of spares as per defined Min - Max level.- Ensure quarterly inventory audit . Justification and action plan for variance.Maintenance Perspective- Ensure availability of machine whenever there is production.- Monitoring Breakdown, Preventive, Predictive & Proactive maintenance.- Ensure 5S Activities, Implementation of Kaizens - (Reduce cycle time, Quality Maintenance & Energy Saving).- Documentation for getting TS 16947 & ISO 14001 certificate.- Ensure carry out in house low cost automation projects to meet customer expectation.- Involving Maintenance personnel while deciding new machines to ensure machines spares as per standards to reduce maintenance time and cost.- Ensure Automation as per specific requirement of production.- Energy conservation activities initiation and monitoring.Business Planning & Controlling P&L Account- Preparation and execution of yearly plant budget (revenue and Capex)- Effective cost control with optimization of resources.- Control on cash flow, Inventory and working capital.Risk Management- Risk assessment and contingency planning of all kind of operational risks associated with business. - Risk cards to be made and to be reviewed monthly.Administrative & Safety Perspective- Effective contractor management and Implementation of contractor performance score card. - Responsible for Effective Trade Union management.- Manpower planning, recruitment, productivity control, and KRA implementation, Implementation of performance driven culture, IDP, On-the-job training for accomplishing greater operational effectiveness efficiency. - Managing and controlling all aspects of various statutory compliances along with co-coordination with local regulatory authorities.- Ensuring high-quality house-keeping and adherence to other shop floor compliances.- Responsible for overall safety of employees and plant machinery as factory manager. To take initiatives and introduce robust system of safety, Health and Environment management.People Perspective- Motivate the team for high morale and help them in grooming their talents.- Employee engagement activities to be done through adequate communication and celebrating the achievements.- Identifying the training needs and help them in closing the gaps.- Handling employee grievances and resolving them amicably.Development Perspective- Establish a system of reports and communications for all information and for feedback to the entire plant functions.- Develop ongoing liaison with key opinion leaders, attending & updating various conferences and seminars for team & self development, touching base with other organizations of same industry to ensure that significant developments are identified & applied.- Ensure that the systems are in place whereby whole plant functional teams are aware with the SOPs and the code of conduct to be followed.- Responsible for performance appraisal of all plant employees and for providing training and development opportunities including succession planning.- Ensure effective functioning across the cross-functional teams.MIS Reports- Responsible for providing MIS charts Power point presentation comparison sheets for Target Planned Vs Achieved defects reported inventory WIP finished , Corrective and Preventive Action (CAPA) taken to management on daily weekly monthly basis etc.
